Method and mechanism for assembling cartons



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' I o z arzfiezzai Patented Ana 1 4 METHOD AND MECHANISM FOR Assim- BLING CARTONS Leon Benoit and E. Joseph Kanabay, Chicago, Ill., and Arthur Edmund Brown and William Vaughan, London,

Ontario, Canada;

said

Kanabay, said Brown, and said Vaughan assignors to Said Benoit Application March 1, 1933, Serial No. 659,128

31 Claims.

The mechanism of the present invention is designed primarily for the purpose of assembling egg cartons of the style and character which when set up provide for two rows of separated 5 compartments arranged on opposite sides of a medial double walled partition in conjunction with closing flaps which are adapted to be folded over the respective rows of compartments to provide separate covers for the rows of eggs.

In cartons of this character it is customary to construct the body of the carton from a single sheet of paper board, and to insert the separate cross walls constituting the cross divisions through registering slots formed in the medial double walled partition, so that each cross wall extends oppositely from the medial partition and serves to separate the compartments on opposite sides thereof. A carton of the general style involved is set forth and described in Letters Patent of the United States, No. 1,768,023, issued June 24, 1930, to Leon Benoit.

In the shipment of cartons of this general character it is customary to properly score the body of the carton and to insert therethrough a set of cross walls, and to nest the cross walls into .fiatwise or overlapping relation, and to turn down the. upper portion of the carton body thereover into flatwise or knock-down relation, so that a consignment of cartons will occupy but a small space during shipment. In setting up such a carton, the cross walls are spread into transverse relation and hooked into the walls of the carton in the intended manner to provide the rows of compartments, after which the eggs are inserted and the cover flaps folded over the top to enclose the package.

The present invention relates to the method which includes the feeding forward of the carton blanks; breaking them down along the score lines; doubling the blanks along a medial folding line to present a double wall thickness for the formation of the registering slots; the slotting of the carton blanks; feeding out a set of cross walls, and advancing them in edgewise relation toward and through the registering slots; nesting the inserted cross walls to overlap one another; folding down the upstanding portions of the carton blank to overlie the nested cross walls; and finally walls to the slots; and in view of the fact that the .slots are but slightly wider than the thickness of the cross walls, it is necessary to accurately position and hold the parts during the inserting operation, and the mechanism of the present invention is designed to meet these requirements andto rapidly and accurately assemble and deliver the cartons and to automatically perform most of the operations involved without the necessity for human manipulation.

The invention further involves the use of synchronized mechanisms so constructed and ar- I ranged as to perform the several operations in sequence and in timed relation, and to at all times guide and hold the cartons and the partitions in such a way as to avoid the possibility of displacement or failure of registration even when operating at a high rate of speed.

Further objects and details will appear from a description of the invention in conjunction with 15' the accompanying drawings, wherein,-

Figure 1 is a diagrammatic view of the several co-ordinated and combining mechanisms involved in the folding and die cutting of the carton blank in preparation for the later insertion of so the cross walls;

Fig. 2 is a perspective view showing the formation assumed by the carton body at various stages of the operations involved in Fig. l, and showing a carton in progress through the overlying mecha; anisms illustrated in Fig. 1;

Fig. 3 is a side elevation of the mechanism which is diagrammatically illustrated in Fig. 1;

Fig. 4 is a longitudinal sectional elevation through the blank feeding mechanism illustrated 0 at the extreme left of Fig. 1;

Fig. 5 is a similar view in part showing the lowermost blank advanced to the bite of the feed roller;

Fig. 6 is a longitudinal sectional elevation of the mechanism for initially bending the carton blank along the scoring lines and folding the medial portion of the blank on itself to afford the, double walled medial partition, the section being taken on line 6-6 of Fig. 9; I

Fig. 7 is a sectional detail taken on line 77 of Fig. 6 showing the vertically disposed feed rollers for engaging the sides of the medially folded carton blank;

Fig. 8 is a fragmentary detail showing the pro- 105 vision of scoring ribs and co-operating channels in certain of the feeding rollers as a modification where it is desired to perform the scoring operations within the machine itself rather than in no the preliminary operation of cutting and printing the carton blanks;

Fig. 9 is a cross sectional elevation of the bending mechanism shown in Fig. 6, the section being taken on line 9-9 of Fig. 3;

Fig. 10 is a detail showing the bending blade and associated parts in depressed position and with the corresponding cross configuration of the blank shown in cross section;

Fig. 11 is a cross sectional elevation through the die punching mechanism of Fig. 1, to the right of the bending mechanism which forms the slots in the carton blanks, the section being taken on the line 1l11of Fig. 3; I 4

Fig. 12 is a sectional detail taken on line 12 of Fig. 11, showing a blank positioned to be die cut;

Fig. 13 is a sectional detail taken on line 13 of Fig. 12, and looking down on the guideway in the die cutting mechanism through which the blanks travel;

Fig. 14 is a plan view of the die cutting mechanism taken from above and showing the means for feeding the blanks to and beyond the die cutting mechanism to the stacker shown at the right of Fig. 14;

Fig. 15 is a perspective detail from above showing the mechanism for guiding and positioning the blanks within the die'cutting mechanism;

Fig. 16 is a diagrammatic side view of the mechanisms involved in the feeding and insertion of the cross walls through the folded carton blanks and in the final folding and stacking of the blanks;

Fig. 1'7 is a perspective view showing the formation of the blanks and cross walls at the several stages of progress through the mechanisms of Fig. 16;

Fig. 17 is a cross sectional view on line 17 of Fig. 1'7, showing a carton blank having a cross wall inserted therethrough;

Fig. 18 is a perspective view of a carton completely assembled and with the covers closed;

Fig. 19 is a side elevation of the mechanisms which are diagrammatically illustrated in Fig. 16;

Fig. 20 is a top or plan view of the stacker shown at the right of Fig. 19;

Fig. 21 is a cross sectional elevation taken through the assembling mechanism and showing the means for feeding the folded carton blanks into upstanding position to receive the cross walls;

Fig. 22 is a detail showing certain of the mechanisms of Fig. 21 in a different operating position;

Fig. 23 is a cross sectional elevation taken on line 23 of Fig. 19, showing the mechanism for feeding and advancing the cross walls for insertion through the carton blanks;

Fig. 23 is a plan view of the mechanism shown in Fig. 23;

Fig. 24 is a detail of a portion of the same mechanism in a different position of operation;

Fig. 25 is a cross section taken on line 25 of Fig. 23, showing the mechanism for upwardly tilting the cross walls';

Fig. 26 is a similar view showing the a different position of operation;

Fig. 27 is a detail showing the cam and connections for operating the clamping mechanism for lifting the carton blanks after insertion of the cross walls, the same being viewed on line 27 of Fig. 19;

Fig. 28 is an enlarged detail of the same cam mechanism;

Fig. 29 is a detail in plan of the mechanism for parts in Fig. 30 is a sectional detail taken on line 30 of Fig. 29; i

Fig. 31 is a cross sectional view of the same mechanism taken on line 31 of Fig. 19;

Fig. 32 is a detail taken on line 32 of Fig. 19;

Fig. 33 is a perspective view of the kicker arm for forcing the folded cartons into the final stacker;

Fig. 34 is a plan view of the terminal portion of the machine, looking downwardly along the plane indicated by the line 34-34 in Fig. 19;

Fig. 35 is a plan view of the driving mechanism viewed from the plane 35-35 of Fig. 19;

Fig. 36 is a vertical sectional elevation taken on the line 36 of Fig. 21, showing a folded carton blank with the inserted cross walls in position;

Fig. 37 is an enlarged sectional detail taken on line 37 of Fig. 36;

Fig. 38 1am edge view of a carton blank in progress through the guideway which serves to progressively nest the cross. walls on one another;

Fig. 39 is a plan view of the guides for feeding the cross walls edgewise toward the carton blank; and a modified arrangement for delivering blanks thereto; and

Fig. 40 is a sectional elevation taken on line 40 of Fig. 39.

Carton folding mechanism The first group of operations involved in the present method has to do with the folding and dieing of carton blanks 1), made desirably of a suitable paper material, in preparation for the reception of the cross walls in conformity with the scheme of operations diagrammatically indicated in Figs. 1 and 2. In these figures, the carton blanks in flat unfolded form are first introduced into the mechanism in the form of a vertical stack carried by a hopper A. It is customary to first print the carbon blanks with the intended lettering and provide them with a series of longitudinal score lines or ribs, as indicated at the left of Fig. 2. The cartons in fiatwise position are fed forward through rollers B into a bender C in the nature of a press which breaks down the blank along the score lines and gives it the configuration indicated in the second position illustrated in Fig. 2. In this condition, the medial. portion of the blank is folded to V-form along a medial score line a.

The V-shaped medial section has outwardly extending on either side therefrom what may be termed a wing section bent along score lines D, c and d. These score lines divide the carton blank into two duplicate divisions, and when the carton is ultimately assembled, each section will assume a trough-shaped configuration with the score line b constituting the inverted ridge of the carton, with the section e subtended between the score lines b and c constituting the oblique outer wall, with the section f subtended between the score lines 0 and d constituting the top, and with the marginal section beyond the score line d constituting a flap to tuck in for the purpose of closing the carton, as clearly illustrated in Fig. 18.

After the carton blank has been broken down to the configuration just described, it is medially folded and fed forward to a die punching mechanism D, within which'it is subjected to the action of dies which cut out the vertical slots g which traverse the score lines b so that each section of the carton blank on opposite sides of the medial score line a will be similarly. punched. Simultaneously, the medial score line a is died. to cut out half-circular notches h which being out along the medial line constitute circular holes in the complete carton blank.

, From the die punching mechanism, the carton blanks are fed forwardly in edgewise relation to a stacker E within which the carton blanks are compressed into a horizontally extending stack with the folded carton blanks standing on their folded edges, as indicated at the right of Fig. 2.

All of the mechanisms, A, B, C, D, and E, are carried upon a table supported upon corner legs 51 at a convenient height above the floor (see Fig. 3). The hopper A is elevated above the table upon a frame comprising comer standards 52 which support an open-work hopper having corner uprights 53 of angle formation, which are properly spaced to permit a stack of blanks to be arranged in vertical column form. and supported in part upon a fixed floor plate 54 (see Fig. 4) and in part upon an obliquely disposed slide plate 55 provided near its rear edge with a shoulder 56 adapted to engage the rear edge of the lowermost blank of a column and feed the same forward through a narrow slot 57 formed between the fixed plate 54 and an adjustable forward cross ate 58.

The slide plate 55 is carried-.by a fin 59 which is slidably mounted upon a fixed plate 60, upon which it is suitably guided and actuated by means of a lever 61, to the upper end of which is pivoted the outer end of a link 62, the inner end of which is pivoted to a tongue 63 depending from the fin 59, so that as the lever is actuated a reciprocating motion will be imparted to the slide plate sufiicient in amplitude to bring the lowermost blank into the bite of the roller feeding means B presently to be described.

The lever 61 is fulcrumed upon a pin 64 carried between brackets 65 mounted upon the table 50, and the lower end of the lever connects with a pitman 66 terminating in a head 67 provided with a slot 68 which embraces a cam shaft 69 carrying a cam 70 having a groove '71 which receives a roller '72 on the head 6'7, which arrangement serves to impart the timed movements of reciprocation required in feeding the blanks forwardly (see Fig. 4).

The roller feed means comprise an upper roller '73 and a lower roller 74 mounted upon roller shafts 75 and '76 respectively. The lowermost roller is power driven by means of a sprocket chain 77 which drives a sprocket 78 on the shaft 76. The chain 7'7 passes around a driving sprocket '79 carried by the cam shaft 69 which imparts constant rotation to the rollers. The upper and lower rollers are suitably entrained to impart positive rotation to the upper roller. The upper roller is pressed against the lower roller by springs at each end thereof (not shown), the pressure being adjusted by means of an adjusting screw 80 to accommodate carton blanks of varying thickness. The rollers just described are carried by standards 81, or in any other suitable manner.

The blanks fed through the rollers 73 and 74 are engaged by powerdriven spaced pairs of forwarding rollers 82 and 83, which deliver the blanks flatwise into the bender C shown in Fig.

6, and in order to prevent the rear edges of the blanks from springing upwardly, they are guided into and through the rollers 82 by obliquely disposed shoes 84, the forward ends of which extend into the bender C, which bender (see Fig. 9) comprises spaced anvil plates 85-85 mounted upon standards 88-86 suitably spaced upon opposite sides of the medialline of advance of the carton blanks. Each of the anvil plates 85 comprises a flat body section 87 and a downwardly flaring wing section 88. In the gap between the two anvil plates and below the level thereof is located a central trough-shaped plate .89 adapted to receive the inverted ridge formed by the pressing down of the carton blank along the medial score line during the operation of 85 configuring the carton blank, as indicated in the second position of Fig. 2.

The anvil members above described coact with spaced presser members 90-90, eachof which comprises a fiat body portion 91 adapted to register with the flat body portion 87 and an obliquely disposed wing portion 92 adapted to register with the anvil wing portion 88. The trough-shaped anvil member 89 coacts with a blade-like folder 93, the center portion 94 of which is cut away from the body portion in the form of a blade which is pivoted to a link 95.: The presser members are carried-by a presser head 96, the ends of which are slidable upon vertical posts 97, and the presser head is 20- tuated at each end by a pitman 98, the lower end of which is provided with a head'99 pivoted upon a cross rod 100, the ends of which are carried by rocker bars 101 actuated by cams 102 mounted upon the came shaft 69 suitably journalled within hangers 104 depending from the table 50 (see Figs. 3 and 9). The cam shaft 69 is driven by a sprocket 105 and chain 106 driven by a motor 107. i

As shown in Fig. 10, the mechanism abovellO described serves to break down the carton blank along the score lines a, b, c, and serves to clamp the carton blank, save for the margins beyond the score lines d which project free beyond the anvil members. These projecting margins are bent by the action of bending fingers'108-108, each of which is in the form of a swinging lever pivoted upon a pintle 109 carried by a block 110. Each of the swinging fingers 108 is actuated by a pitman 111, the outer end of which is pivoted to the associated finger, and the inner end of which is pivoted to a lug 112 carried by a rack, bar 113. The two rack bars stand in spaced relation to one another and on opposite sides of and in train with a driving pinion- 114, so that the rotation of the pinion will cause the two rack bars to move in opposition to one another and hence cause the two folding fingers to advance and recede in opposition from the position shown in Fig. 10.

The rack bars 113 are guided within slots in a cross guide head 115 (Fig. 6) and the pinion is carried by a vertical shaft 116 which extends through a vertical sleeve 117 and has its lower end journalled within ball bearings 118. The shaft 135 116, at its lower end, has keyed thereon a driving pinion 119 which meshes with a rack 120 slidably mounted within a guide plate 121 and actuated by means of a pitman 122 bifurcated at 7 its head end 123 to embrace the cam shaft 69, 1&0 w hich shaft carries a cam 124 having a groove .125 which receives a roller 126 carriedby the 

